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0.076" is likely going to be the winner.

What kind of parts are you attempting to make?

If the backlash opened up there was probably not enough preload on the carrier bearings. Why did you set the pinion preload so high? I thought previously you had preload spot on? ~12-15in/lbs starting torque on new bearings. 40in/lbs is way too high for starting torque.

Toyota should pay you for that photo.

Chaos! Looks real cool in slow motion right before failure.

Yep. Just remember that 1/2 critical speed can also potentially induce vibrations as well.

With those inputs I see these RPM's Critical speed - 11295 1/2 critical speed - 5648 You could hit the 1/2 critical speed at around 92MPH with your tire size and rear end ratio. Critical speed would be around 188MPH These values may be slightly lower by a couple MPH or so, due to the necked...

I am assuming 40inches between tube welds. Though the necked down sections before the weld will affect the calculation some. Need your full tire size also. Your gear ratio is 4.56 yes? I can give you some numbers once you send that info over.

I can run some calculations on it for you later. What is the tube length between the welds?

Get out of here with your logic.

That will happen when the thermostat has not yet opened. No flow through thermostat = no temp registering on stock gauge mounted in thermostat housing Same reason you can get heat inside the cabin on cold days AND still have a radiator cold out front. Coolant is still circulating no matter...

Sounds promising.

Any updates?

Sounds like you got it working. Has it quiet down any more now with more miles on it? Glad you persevered and figured it out. Still strange the ring had damage new out of the box, i have never encountered that before. You managed to work through a lot of problems, nice job

I've just returned to the country, have been out for awhile. I will give a read when I have some free time.

Looks good. Nice find on the pinion imperfection and polish. You should be good to run it now. I hope it's the last time you have to tear this down! Pinion pattern looks good, not tailing much at all to the center, a mark of good depth not too deep.

Can you use yellow marking compound? Contrast on blue is really difficult to see what is going on. Also how are you rotating the diff to get the gear pattern? Holding the pinion with a rag very tightly in the hand and rotating the carrier is the preferred method. (both directions) I have tried...

Yeah they do have some automated systems to assist with shim selection and assembly. They are not all hand built, too time consuming. (unless you visit bespoke plants like Acura PMC, Lexus Motomachi or Nissan Yokohama GT-R engine plant) I have spent some time in a number of different Automotive...

I will send over my method to you later today. This is one instance where the TSRM gets it wrong, there is a better method. Even at the factory they never set preload correctly on the carrier bearings, that and I have run across many with big gouges in the steel plate from the cast iron. My...

1. Carrier shim thickness should add up to ~.236-.237" give or take. Actual thickness for each are honestly all over the place, they are almost never the same. Sometimes .118+.121, or .114+.123, or .118+.119 How are you installing the carrier into the case, what order are you placing the...